1989 kx125 restoration master thread

[queen of spodes]

Top end finished.  New old stock power valves operate smooth as silk.  Need to put the studs in, and it'll be ready to bolt on.




Also got my Mitaka clutch basket in from the UK.  Wish I could find a Mitaka clutch hub to match, but I'll try and track down a NOS hub next.  One in the bike is shot (grooves).

[sandblaster]

We should be getting a ride report soon 

[motojason]

Also got my Mitaka clutch basket in from the UK. 

That basket is sweet!

[LukeG]

I picked up a Mitaka basket for my 250. How do they hold up?

[queen of spodes]

Anyone post here from England?   I needs a part, but the seller isn't shipping direct to the states.   Please PM me.

[queen of spodes]

Thought I would put the front wheel and brake on tonight




Trouble with the DRZ400S brake caliper I got as an upgrade.  The DRZ's banjo slot is on the bottom/back of the front brake assembly.  OEM slot was on the other side.  Can't get this to lineup.

[queen of spodes]

Got a little more work done today. 

New rear brake reservoir, ready to bleed once I have the wheel installed.


First coat of high heat paint on the expansion chamber

[queen of spodes]

Taking apart the OEM clutch basket








Out with the old, in with the new


These rubber bumpers were a pain to install on the new Mitika hub


So was the gear. I used C clamps to help pull it down over the dampers


Ready to assemble the clutch pack including a NOS clutch hub (one with the bike had grooves)

[queen of spodes]

Clutch pack installed except for one small detail...


I'm missing one of the clutch spring seat/washers.  The spring holder is AL and I don't want to run the springs right against that. 

Where do I find one of these little things?  Kaw didn't sell them separate.

[bens87braap]

something doesnt look right My manual doesnt seven show those washers I no that mine doesnt have them 

[queen of spodes]

Yeah the more I looked at the parts fiche the more I realized these washers were "home made" by previous owner.  When I pried them off, well.. they were held in place by orange RTV.   In the trash they went.

Had to order some new clutch spring bolts and a $10 clutch hub nut, so it will be at least a week before I can continue putting bottom end together.

[bens87braap]

Awesome at least you getting somewhere it will be making braap noises soon 

[queen of spodes]

Anyone here remember wrenching on these older KX125's?

Curious about torquing down the clutch spring bolts.. the manual calls for 82 inch pounds (about 7 ft lbs) of torque.   The trouble I found in test fitting with some older bolts I had is that I don't reach this torque until the spring is completely compressed.   I can scan the manual to show how the pieces fit together, but the image bens87braap posted above is pretty clear.   

Am I missing something here?

[bens87braap]

Mine was same fully compressed springs before i met the right torque I thought that was strange and Im missing some adjustment in the clutch but I think its the cable.  I just figured I would want the springs tight on Install as the clutch isnt pulled in?  Someone correct me if im wrong

[queen of spodes]

2004 RM125 master cylinder fitted to my KX.  This generation RM brakes were superb.